Hydroseed substrate and method of making such

ABSTRACT

An application for a substrate for mixing with other ingredients such as water, seeds, fertilizer, wetting agents and dye, to produce Hydroseeding slurry. The substrate includes cellulose materials (e.g. cardboard, paper and/or wood) and an absorbent. In one embodiment, the absorbent is material known as diaper fluff that is created during the production of products such as disposable diapers. The absorbent or diaper fluff improves moisture retention, improves viscosity and reduces friction, improves coverage of the hydroseed mixture.

RELATED APPLICATIONS

This application is a continuation-in-part of co-pending applicationSer. No. 12/492,273, titled “HYDROSEED SUBSTRATE AND METHOD OF MAKINGSUCH”, attorney docket number 2647.3, filed Jun. 26, 2009, thedisclosure of which is hereby included by reference.

FIELD

This invention relates to the field of agriculture and more particularlyto a hydroseed substrate and a method of making such.

BACKGROUND

Hydroseeding is well known and consists of mixing seeds, water, and asubstrate into a slurry and spreading the slurry over an exposed area ofsoil. The substrate provides a cover mat to the soil, holding moisturein while reducing sunlight on the soil, thereby preventing weed seeds inthe soil from sprouting. Often, fertilizer, minerals, dyes and/ortacking agents, etc, are added to the slurry to improve germination,moisture retention and growth.

Hydroseeding is an improvement over traditional soil preparation andbroadcast seeding since it promotes quick germination and provides mulchto reduce soil erosion. Hydroseeding is a lower cost alternative to sod,requiring less preparation, less transportation costs, lower materialcosts, less labor and faster deployment.

Hydroseeding is also referred to as hydraulic mulch seeding,hydro-mulching or hydra-seeding, and includes a tank of slurry. Theslurry is sprayed evenly over exposed soil. Hydroseeding is usuallyperformed using a truck specifically designed for Hydroseeding and thetruck usually has a tank, air compressor for pressurizing the tank orother means for distributing the slurry, a hose to transport the slurryfrom the truck and a nozzle that forms a spray of slurry under anoperator control. Given such a device, a single operator is capable ofseeding a very large area in a matter of minutes. Hydroseeding has alsobeen performed from low-flying aircraft in areas that are without anyroad infrastructure such as forests, in particular, after a forest fire.In such, it is anticipated that Hydroseeding is performed without seed(e.g., a slurry of a substrate, minerals, fertilizer and water) tore-grow an area of the forest without introducing non-native plantspecies.

Hydroseeding is also used to seed areas with other plant seeds such aswildflower seeds or combinations of grass seed and other plant seeds.

When introduced in the early 1950s, shredded and ground newspaper wasoften used as the substrate. Later, more advanced substrate formulaswere deployed including components such as paper, wood fibers andpolymers. For example, U.S. Pat. No. 6,158,167 to Spittle describesmulch flakes made from finely divided paper and/or wood with addedsurfactants. This patent claims that, once sprayed on the ground, theseflakes reduce water run-off and soil erosion.

Current substrates typically are made from grinding wood fiber (100%) ora mixture of wood fiber and newspaper (e.g., 70% wood fiber and 30%newspaper) and adding dye and surfactants.

What is needed is a substrate that will improve water absorbency whilemaintaining a homogenous viscosity of the slurry.

SUMMARY

The present invention includes a substrate for mixing with otheringredients such as water, seeds, fertilizer, wetting agents, dye, toproduce Hydroseeding slurry. The substrate includes any cellulosematerial such as paper, cardboard and wood along with a material knownas diaper fluff (tampon fluff, adult diaper fluff) and/or linearpolyacrylamide. The diaper fluff improves moisture retention, improvesviscosity, reduces friction and improves coverage.

In one embodiment, the cellulose material is cardboard (e.g.double-line, Kraft fibers) and/or paper (e.g. recycled newspaper). Inother embodiments, the cellulose material is wood (e.g. wood shavings,mulch, wood fibers). In other embodiments, the cellulose material is anycombination of cardboard, paper and wood.

In another embodiment, a Hydroseeding substrate is disclosed includingup to 99 percent by weight ground cardboard, up to 99 percent by weightground paper, up to 99 percent by weight ground wood fiber, and at least1 percent and less than 10 percent of ground diaper fluff or linearpolyacrylamide.

In another embodiment, a method of making a Hydroseed slurry isdisclosed including providing diaper fluff and cellulose and thengrinding the cellulose into a substrate then adding the diaper fluff orlinear polyacrylamide to the substrate. The substrate is then mixed withwater and seed to form a slurry.

In another embodiment, method of Hydroseeding is disclosed includingproviding diaper fluff and cellulose then grinding the cellulose into asubstrate. Next, the diaper fluff or linear polyacrylamide is added tothe substrate. Next, the substrate is mixed in a Hydroseed mixer with,water and seed into a slurry. The slurry is pumped through a nozzle andsprayed on soil where the seed is to grow.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be best understood by those having ordinary skill inthe art by reference to the following detailed description whenconsidered in conjunction with the accompanying drawings in which:

FIG. 1 illustrates a schematic view of a hydroseed manufacturing system.

FIG. 2 illustrates a flow chart of hydroseed manufacturing.

FIG. 3 illustrates a flow chart of deployment of the hydroseed.

DETAILED DESCRIPTION

Reference will now be made in detail to the presently preferredembodiments of the invention, examples of which are illustrated in theaccompanying drawings. Throughout the following detailed description,the same reference numerals refer to the same elements in all figures.

Referring to FIG. 1, a schematic view of a hydroseed manufacturingsystem is shown. Diaper fluff is a waste byproduct of, for example,disposable diaper production 30 (or tampon production, etc.) and is agood source of linear polyacrylamide (PAM). During the production ofdisposable diapers 30, etc., fibrous material is cut, trimmed andshaped, producing disposable diapers 32, as known in the industry. Thetrimmings become waste 34, known as diaper fluff 34. Diaper fluff, bydesign, is highly absorbent. Disposable diapers 32 need to absorb and/orcoagulate liquids (urine) and, therefore, diaper fluff or linearpolyacrylamide (PAM) 34 is an excellent source of a material thatabsorbs and/or coagulates liquids (e.g. water). The absorbency ofdiapers 32 and diaper fluff 34 is enhanced by several materials includedin the diaper fluff 34 such as cellulose pulp, linear polyacrylamide(—CH₂CHCONH₂—), polymers, superabsorbent polymers, copolymers ofacrylamide C₃H₅NO, polymers, etc. Superabsorbent polymers are polymersthat can absorb and retain large amounts of a liquid relative to theirown mass or weight. This list refers to a group of absorbents.

Diaper fluff 34 is an excellent source of these absorbents. Diaper fluff34 and/or these absorbents provide absorbency and/or coagulationcharacteristics to the hydroseed mixture. It has been determined thatthe addition of these absorbents (e.g. diaper fluff or linearpolyacrylamide (PAM) 34) to hydroseed substrate greatly improves theviscosity of the slurry (when mixed with water and other ingredients)and the slurry holds and retains more moisture, thereby improvinggermination and seed growth. It is anticipated that diaper fluff orlinear polyacrylamide (PAM) 34 is available as from other sources otherthan diaper production waste. Prior to the disclosed method andcomposition, the waste/diaper fluff 34 went into landfills.

It is also anticipated that diaper fluff or linear polyacrylamide (PAM)34 be obtained from the production of other similar, highly absorbentproducts such as personal hygiene products.

In parallel, paper (e.g. virgin paper, recycled newspaper, newsprint,etc) is collected 42 creating a stock of paper 40. In the past, much ofthe recycled paper 40 was used to create new paper, but there is a limitto the percentage of recycled paper that is used in paper production dueto the breakdown of fibers. The present invention utilizes any paper 40.

Also in parallel, cardboard box manufacturers 50 accept virgin cardboard52 and produce cardboard boxes 54. Since the virgin cardboard 52 startsas sheets or rectangular sections, it is often trimmed, punched or cut,often producing virgin cardboard scrap 56. In the past, the virgincardboard scrap 56 was sent to pulping mills or wound up in landfills.The present invention utilizes any cardboard 56, although virgincardboard 56 is preferred.

Also, in parallel, other forms of cellulous are collected and refined 57through known pulping processes into a pulp. These sources of celluloseinclude, but not limited to, saw dust, wood chips, building scrap, treelimbs and branches, etc.

The hydroseed manufacturing system combines amounts of newspaper 40,virgin cardboard scrap 56 and/or wood in a grinding process 12, grindingthese forms of cellulous into the proper consistency, mixing 14 with anyoptional ingredients such as wetting agents 18 and dyes 20 which areoften added in liquid form. Next, the diaper fluff or linearpolyacrylamide (PAM) 34 is mixed 15 into the material to complete thesubstrate and then packaged 16. For example, the resulting substrate 22is packaged in bales similar to bales in which peat moss is oftendelivered. It is preferred that the diaper fluff 34 be added after anyliquid components 18/20 are thoroughly mixed and absorbed into thecardboard 56 and/or paper 40 and/or wood so the diaper fluff 34 doesn'treact with and/or begin to absorb the liquids 18/20.

The resulting substrate 22 is later (prior to application) mixed withother ingredients in a hydroseed mixer 30 (e.g., a truck designed forHydroseeding). In this, other desired ingredients such as water 25,nutrients 27, seeds 24 and fertilizer 26 are added to the substrate 22forming the slurry that is then sprayed on the area to be seeded.

The addition of diaper fluff or linear polyacrylamide (PAM) 34 providesfor greater water absorption above that of the prior use of cardboardand/or paper without diaper fluff or linear polyacrylamide (PAM) 34. Theresulting slurry 30 holds more moisture, thereby increasing germination.Furthermore, the resulting slurry is more homogenous, having a moreconsistent viscosity, thereby reducing settling in the slurry tank ofthe spreading vehicle and providing a more even application. The diaperfluff or linear polyacrylamide (PAM) 34 also reduces friction of theslurry, making it more slippery, thereby creating fewer clogs in sprayequipment and nozzles. It is anticipated that such provides for agreater coverage area to sprayers. Furthermore, once applied to soil,the coagulation properties of the diaper fluff or linear polyacrylamide(PAM) 34 improves the slurry's ability to reduce erosion, especially onhills or where run-off is possible.

The mixture includes virgin cardboard 56, paper 40 and/or wood that isground together with, diaper fluff or linear polyacrylamide (PAM) 34 toproduce the substrate. Optional dyes and surfactants are added to theground cardboard 56 and paper 40 before introduction of the diaper fluff34 to permit absorption of the dye and/or surfactant since these areoften and preferably in liquid form. The ratio of materials is veryimportant to the resulting substrate 22 and, eventually, the slurry. Iftoo much diaper fluff or linear polyacrylamide (PAM) 34 is added, theresulting slurry will coagulate and not be usable for Hydroseeding. Theideal combination of ingredients is around 70% cardboard 56, 26% paper40 and 4% diaper fluff or linear polyacrylamide (PAM) 34. It has beenfound that virgin cardboard 56 works best, although it is anticipatedthat recycled cardboard is used in some embodiments of the presentinvention. Although recycled paper 40 works well, it is anticipated thatany paper 40 is used in some embodiments of the present invention.

As an example, a preferred formula includes 35 lb of cardboard 56, 13 lbof paper 40 and 2 lb of diaper fluff or linear polyacrylamide (PAM) 34.It is anticipated that a small amount of plastic liner is included inthe diaper fluff 34 and such is not detrimental to the resultingsubstrate 22 and eventual slurry.

In other embodiments, between 1% and 10% diaper fluff 34 is used, theremaining 90% to 99% of the substrate 22 is made up of a combination ofzero to 99% cardboard 56, zero to 99% paper 40 and zero to 99% wood. Forexample, in one embodiment, the substrate 22 comprises 99% cardboard 56and 1% diaper fluff or linear polyacrylamide (PAM) 34. In anotherexample, the substrate 22 comprises 96% paper 40 and 4% diaper fluff 34.In another example, the substrate 22 comprises 80% cardboard 40, 16%paper 56 and 4% diaper fluff or linear polyacrylamide (PAM) 34. Inanother example, the substrate 22 comprises no paper 40, 98% cardboard56 and 2% diaper fluff or linear polyacrylamide (PAM) 34.

It has been shown that the resulting substrate 22 is capable ofabsorbing approximately 1700 times its weight in water whereas the priorsubstrates made of wood fiber or wood fiber and newspaper without diaperfluff are estimated to absorb around 1000 to 1200 times their weight inwater.

Referring now to FIG. 2, a flow chart of the hydroseed manufacturingsystem will be described. The method begins at the diaper manufacturer30, source of cardboard 50, source of paper 42 and source of wood 57. Atthe diaper manufacturer 30, waste 34 (diaper fluff) is collected. At thebox manufacturer 50 (recycler, etc), scrap 56 is collected 72. At thepaper recycling operation 42 (newspaper recycle, book manufacturer,shredder, etc), paper 40 is collected 74. Wood is supplied 57 from anysource of wood chips, saw dust, scrap wood, fallen limbs and branches,etc. The appropriate mix of cardboard 56, paper 40 and wood 57 iscombined 76 and ground 78 into the appropriate particle size then anyadditional ingredients are added 80 such as wetting agents 18 and/or dye20. Since it is preferred that the wetting agent 18 and/or dye 20 arefluids, the wetting agent 18 and/or dye 20 are absorbed in the cardboard56, paper and/or wood 57 before the diaper fluff or linearpolyacrylamide (PAM) 34 is combined/mixed 82. After the diaper fluff orlinear polyacrylamide (PAM) 34 is added and mixed 82, the resultingsubstrate 22 is packaged 84. Although described using specific sourcesof cardboard, paper and/or wood, any other sources of cardboard ,paperand/or wood are anticipated.

Referring to FIG. 3, a flow chart of deployment of the hydroseedntion isshown. Deployment is often performed in a specialized truck or airplane,as known in the industry. The substrate 22 is added 90 to the mixer 30.Water 25 is added 92 and seed 24 is added 94. If needed, fertilizer 26(e.g., nitrogen) is added 96. If needed, nutrients 27 (e.g., iron) areadded 98. The order of adding ingredients is not significant. Thesubstrate 22, water 25, seed 25 and optional fertilizer 26 and nutrients27 are mixed 100 into the slurry and sprayed 102 on the soil wheregrowth of the seeds is desired.

Throughout the description, the term “diaper fluff” refers to anymaterial that is more absorbent than cardboard, paper and/or wood suchas linear polyacrylamide (PAM) (—CH₂CHCONH₂—), polymers, superabsorbentpolymers, copolymers of acrylamide C₃H₅NO, polymers, etc. Diaper fluff34 is an excellent source of some or all of these superabsorbentmaterials and is readily available as waste from other manufacturingprocesses.

Equivalent elements can be substituted for the ones set forth above suchthat they perform in substantially the same manner in substantially thesame way for achieving substantially the same result.

It is believed that the system and method of the present invention andmany of its attendant advantages will be understood by the foregoingdescription. It is also believed that it will be apparent that variouschanges may be made in the form, construction and arrangement of thecomponents thereof without departing from the scope and spirit of theinvention or without sacrificing all of its material advantages. Theform herein before described being merely exemplary and explanatoryembodiment thereof. It is the intention of the following claims toencompass and include such changes.

1. A Hydroseeding substrate comprising: up to 99 percent by weightground cellulose; up to 99 percent by weight ground cardboard; up to 99percent by weight ground paper; and at least 1 percent by weight andless than 10 percent by weight of ground diaper fluff.
 2. TheHydroseeding substrate of claim 1, wherein the ground cardboard isvirgin cardboard.
 3. The Hydroseeding substrate of claim 1, wherein theground cardboard is approximately 70 percent by weight of the slurry,the ground paper is approximately 26 percent by weight of the slurry andthe ground diaper fluff is approximately 4 percent by weight of thesubstrate.
 4. The Hydroseeding substrate of claim 1, wherein thesubstrate comprises approximately 96 percent by weight paper andapproximately 4 percent by weight diaper fluff.
 5. The Hydroseedingsubstrate of claim 1, wherein the paper is recycled newsprint.
 6. TheHydroseeding substrate of claim 1, wherein the cellulose is a pulprefined from wood fiber.
 7. The Hydroseeding substrate of claim 1,wherein the cellulose is a pulp refined from wood chips.
 8. TheHydroseeding substrate of claim 1, further comprising a dye.
 9. TheHydroseeding substrate of claim 1, further comprising a wetting agent.10. A Hydroseeding substrate comprising: up to 99 percent by weightground cellulose; up to 99 percent by weight ground cardboard; up to 99percent by weight ground paper; and at least 1 percent by weight andless than 10 percent by weight of linear polyacrylamide.
 11. TheHydroseeding substrate of claim 10, wherein the ground cardboard isvirgin cardboard.
 12. The Hydroseeding substrate of claim 10, whereinthe ground cardboard is approximately 70 percent by weight of theslurry, the ground paper is approximately 26 percent by weight of theslurry and the linear polyacrylamide is approximately 4 percent byweight of the substrate.
 13. The Hydroseeding substrate of claim 10,wherein the substrate comprises approximately 96 percent by weight paperand approximately 4 percent by linear polyacrylamide.
 14. TheHydroseeding substrate of claim 10, wherein the paper is recyclednewsprint.
 15. The Hydroseeding substrate of claim 10, wherein thecellulose is wood fiber.
 16. The Hydroseeding substrate of claim 10,wherein the cellulose is a pulp refined from wood chips.
 17. AHydroseeding substrate comprising: up to 99 percent by weight groundcellulose; up to 99 percent by weight ground cardboard; up to 99 percentby weight ground paper; and at least 1 percent by weight and less than10 percent by weight of an absorbent.
 18. The Hydroseeding substrate ofclaim 17, wherein the absorbent is one or more polymers selected fromthe group consisting of linear polyacrylamide (—CH₂CHCONH₂—), polymers,superabsorbent polymers and copolymers of acrylamide (C₃H₅NO) polymers.19. The Hydroseeding substrate of claim 18, wherein the ground cardboardis approximately 70 percent by weight of the slurry, the ground paper isapproximately 26 percent by weight of the slurry and the absorbent isapproximately 4 percent by weight of the substrate.
 20. The Hydroseedingsubstrate of claim 18, wherein the substrate comprises approximately 96percent by weight paper and approximately 4 percent by weigh of theabsorbent.